Synthetic fiber containing plant fatty acids and method for manufacturing same

ABSTRACT

Disclosed are a synthetic fiber comprising a plant fatty acid and a method for manufacturing the same. The method comprises incorporating a plant fatty acid in an amount of from 0.1 to 10.0 wt % into a fiber-formable polymer; and melt-spinning the plant fatty acid-incorporated polymer. The synthetic fiber comprises a plant fatty acid in an amount of from 0.01 to 1.0.0 wt %, and emanates a plant fragrance. In addition to being superior to general synthetic fibers in physical properties including strength and elongation, the synthetic fiber exhibits excellent bulkiness, elasticity, whiteness, touch sensation, hygroscopicity, dyeability, and gloss. Further, the fiber is highly antistatic and gives off a plant fragrance, so that it is useful as a material for high-quality clothes.

CROSS-REFERENCE TO RELATED U.S. APPLICATIONS

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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

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NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT

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REFERENCE TO AN APPENDIX SUBMITTED ON COMPACT DISC

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BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a plant fatty acid-containing syntheticfiber and a method for manufacturing the same. More particularly, thepresent invention relates to a plant fatty acid-containing syntheticfiber which exhibits excellent physical properties including strengthand elongation and is significantly improved in appearance andanti-staticity, and a method for manufacturing the same.

2. Description of Related Art Including Information Disclosed Under 37.CFR 1.97 and 37 CFR 1.98

Synthetic fibers including polyester fibers are widely used as materialsfor clothes thanks to their excellent strength, elongation anddurability.

However, synthetic fibers are disadvantageous in that they are stiff,give a feeling of repulsion upon contact with the skin, and give rise tosignificant static electricity.

A lot of effort has been put into overcoming these problems. Exemplaryare the disclosure of Korean Patent Nos. 10-0726409 and 10-0515808,which describe the direct coating and fixation of synthetic fibers withplant extracts. However, the synthetic fibers coated with plant extractsdo not persistently exhibit antibacterial activity because the extractsbleed out of the fibers upon washing.

A method of microencapsulation of plant extracts in which the plantextracts are trapped inside microcapsules and the microcapsules areattached to the surface of the fibers was suggested as a solution to theproblem. This method was however problematic in that the microcapsulesreadily separate from the fibers under the conditions of friction,washing, light exposure and the like.

Melt spinning may be contemplated as a method for manufacturing plantextract-containing fibers. However, typical melting points for syntheticfibers are on the order of 200˜300° C. at which plant extracts orvegetable oils, if used in advance of melt spinning, may undergoevaporation, degradation and/or denaturation and thus cannot beincorporated into fibers or will not exhibit sufficient functionalityeven if incorporated.

In an effort to solve this problem, Korean Patent No. 20 10-0910241teaches an electrospinning method by which tine fibers can be drawn atlow temperatures from a solution of (a) at least one component selectedfrom among plant extracts and vegetable essential oils and (b) at leastone fiber-formable polymer in (c) a solvent.

In electrospinning, a solution is erupted from a nozzle by theelectrical force formed between a collector and the nozzle and becomes ajet stream which is then dried into nanofibers as the solvent evaporateswhen it reaches an incomplete region.

Electrospinning is considered to be a solution to most of the problemsassociated with conventional spinning methods. However, electrospunfibers exhibit poor mechanical properties because they are notaccompanied by the strength enhancement imparted by the molecularorientation of the polymer. For this reason, electrospun fibers are notused for clothes.

Korean Patent No. 10-0563560 discloses “a phytoprotein synthetic fibre”which is composed of vegetable protein and polyvinyl alcohol. Based onthe total amount of these two materials, the amount of the vegetableprotein that is used is 5 to 23 parts and the polyvinyl alcohol (B,parts) is used in an amount of from 77 to 95 parts.

The phytoproteins are prepared from beans, peanuts and cottonseeds bypulverizing them to separate proteins in a wet manner to separateproteins, skimming the proteins and coagulating the skimmed proteins.

The fibers manufactured using this method are highly permeable to airand have properties similar to those of cashmere, but are not unsuitablefor use in clothes due to their poor strength and durability.

In order to reduce the generation of static electricity in syntheticfibers, electroconductive carbon black or metal has been employed in thefibers (Korean Patent Application No. 10-2006-0138108).

However, the electroconductive fibers are too expensive to be usedsuitably in general clothes.

TECHNICAL PROBLEM

It is an object of the present invention to provide a synthetic fiberwhich has significantly improved general physical properties includingstrength and elongation.

It is another object of the present invention to provide an antistaticsynthetic fiber.

It is a further object of the present invention to provide a syntheticfiber having excellent appearance and yarn evenness.

It is still a further object of the present invention to provide aninsect-repellent synthetic fiber.

It is still another object oldie present invention to provide asynthetic Fiber exhibiting superior dyeability and sensation whentouched.

It is yet another object of the present invention to provide a syntheticfiber letting off a plant fragrance.

BRIEF SUMMARY OF THE INVENTION

In accordance with an aspect thereof, the present invention provides asynthetic fiber containing a plant fatty acid in an amount of from 0.01to 10.0 wt %.

In accordance with another aspect thereof, the present inventionprovides a method for manufacturing a synthetic fiber, comprisingincorporating a plant fatty acid in an amount of from 0.1 to 10.0 wt %into a fiber-formable polymer and melt-spinning the plant fattyacid-incorporated polymer.

A detailed description will be given of the present invention, infra.

Examples of the plant fatty acids useful in the present inventioninclude linoleic acid, oleic acid, stearic acid, palmitic acid, licanicacid, and ricinol acid, which are abundantly found in linseed oil,sunflower seed oil, rapeseed oil, camellia oil and castor oil.

Ingredients of linseed oil are summarized in Table 1, below.

TABLE 1 Ingredient Content (g/100g Fatty Acid) Myristic acid 0.04021Pentadecanoic acid 0.02278 Palmitic acid 5.27593 Palmitoleic acid0.05897 Margaric acid 0.06364 Heptadecenoic acid 0.04187 Stearic acid3.47834 Oleic acid 18.56481 Linoleic acid 15.39735 Linolenic acid56.41282 Arachidic acid 0.14637 Gadoleic acid 0.13117 Eicosadienoic acid0.04389 Eicosadienoic acid 0.02286 Heneicosanoic acid 0.04995 Behenicacid 0.12625 Erucic acid 0.01942 Lionaceric acid 0.10388

On the whole, the physical properties of synthetic resins become worsewhen they are mixed with an additive. In contrast, the physicalproperties of synthetic fiber are improved rather than degraded, whichin our opinion is attributed to the formation of chemical bonds betweenthe fatty acids and the fiber-formable polymer.

Extraction of fatty acids may be accomplished using a solvent method ora heat compression method. Preferable is the latter. The reason is thatvolatile matters with low molecular weights are removed naturally fromthe plants during compression at a typical temperature of 80˜220° C.When volatile matters with low molecular weights are contained withinthe fiber-formable polymer, the resulting fibers are likely to have poorphysical properties because the matters are evaporated or degraded atrelatively low temperatures.

Incorporating the antibacterial plant extract into the fiber-formablepolymer may be carded out by (i) coating synthetic resin chips withplant fatty acids, and melt spinning the coated chips or compounding thecoated chips into master batch chips, (ii) preparing a master batch chipin the presence of the plant fatty acids and melt spinning the masterbatch chip alone or in combination with another typical synthetic chip,(iii) feeding plant fatty acids to a melting zone of an extruder, or(iv) adding the plant fatty acids during the polymerization of thefiber-formable polymer.

Preferable is the method of (iii) in order to minimize the thermaldegradation of plant fatty acids. When the method of (iii) is employed,suitable control is necessary to prevent the pressure of the extruderfrom decreasing.

In the method of (i), that is, the method of coating synthetic resinchips with plant fatty acids, it is preferable that drying be conductedusing a rotary-type hot-air drier or a radio-frequency drier least inorder to minimize the thermal degradation of plant fatty acids during adrying process.

To enhance the workability in the method of (i) or (ii), the plant fattyacids may be emulsified with water in the presence of an emulsifier.

Preferably, the plant fatty acids are used in an amount of is from 0.1to 10 wt %. When too little any acid is used, no effects according tothe addition of the fatty acids are detected. On the other hand, anamount exceeding the upper limit makes it difficult to manufacturefibers and has an adverse influence on the physical properties of thefibers.

If necessary, ordinary additives such as antioxidants, thermalstabilizers, viscosity improvers, etc. may be used in the melt spinningprocess.

Additionally, workability in mixing or coating processes may be enhancedby adding a desiccant to plant fatty acids. Also, plant fatty acids maybe heated in air or under an aerobic condition to improve the bindingrate.

ADVANTAGEOUS EFFECTS

In addition to being superior to general synthetic fibers in physicalproperties including strength and elongation, the synthetic fibers ofthe present invention exhibits excellent bulkiness, elasticity,whiteness, touch sensation, hygroscopicity, dyeability, and gloss.Further, the fibers of the present invention are highly antistatic, witha surface resistivity of less than 1.0×10¹⁴ (Ω), and give off a plantfragrance. Therefore, they are useful as material for high-qualityclothes.

DETAILED DESCRIPTION OF THE INVENTION Mode for Invention

A better understanding of the present invention may be obtained throughthe following examples which are set forth to illustrate, but are not tobe construed as limiting the present invention.

Preparation Example 1

After being heated to 180° C., 8,500 kg of linseeds was pressed using anoil press to squeeze oil therefrom. They were left for 15 days to settlesolid matter, after which filtration afforded 2,000 kg of linseed oil.

Example 1

Polyethylene chips were coated with the linseed oil prepared inPreparation Example 1 by incubating 98 wt % of the chips with 2 wt % ofthe oil for 15 days. The resulting coated chips were mixed at a weightratio of 1:2 with ordinary polypropylene chips and melt-spun at 230° C.using a pilot spinning machine to produce 500 g of 150 denier/28 filafilaments.

The raw fibers were knitted into socks and dyed. The socks were found tohave excellent color presentation, gloss and touch sensation and toemanate a characteristic plant fragrance.

Example 2

Using a twin screw master batch extruder (W&P, Germany), 97 kg ofpolyamide chips was mixed with 3 kg of the linseed oil prepared inPreparation Example 1 and extruded in a typical manner into master batchchips. These chips were compounded at a weight ratio of 1:3 withordinary polyamide chips, dried in a typical manner and melt spun at240° C. into 150 denier/28 fila filaments using a pilot spinningmachine.

The fibers were knitted into socks and dyed. The socks were found tohave excellent color presentation, gloss and touch sensation and toemanate a characteristic plant fragrance.

Example 3

A mixture of 3 kg of commercially available rapeseed oil and 97 kg ofpolypropylene chips was used to prepare master batch chips which werethen melt spun at 230° C. into 150 denier/28 fila filaments using apilot spinning machine.

The fibers were knitted into socks and dyed. The socks were found tohave excellent color presentation, gloss and sensation when touched andto be antistatic.

Example 4

A mixture of 3 kg of commercially available castor oil and 97 kg ofpolypropylene chips was used to prepare master batch chips, as stated inExample 3. The master batch chips were then compounded at a weight ratiowith 1:1 with ordinary polypropylene chips and melt spun at 230° C. into150 denier/28 fila filaments using a pilot spinning machine.

The fibers were knitted into socks and dyed. The socks were found tohave excellent color presentation, gloss and sensation when touched.

Example 5

A mixture of 3 kg of commercially available camellia oil and 97 kg ofpolypropylene chips was used to prepare master batch chips, as stated inExample 3. Then, the master batch chips were compounded at a weightratio with 1:2 with ordinary polypropylene chips and melt spun at 230°C. into 150 denier/28 fila filaments using a pilot spinning machine.

The fibers were knitted into socks and dyed. The socks were found tohave excellent color presentation, gloss and sensation when touched.

Example 6

The linseed oil prepared in Preparation Example 1 was added in an amountof 5 wt % into a polymerization test machine immediately before an ESreaction was performed under the following conditions: molar ratio1:1.12; Sb₂O₃ (250 ppm), TiO₂ (3,000 ppm), H₃PO₄ (200ppm); finalreaction temperature 255° C.; reaction time 210 min. Subsequently, a PCreaction was performed for 220 min at a final temperature of 287° C.under a pressure of 0.4 torr to produce 70 g of polymerized chips.

The molar ratio means {(Amount of EG fed/Mw of EG 62.07)/(Amount of TPAfed/Mw of TPA 166.13)}.

A mixture of 70 g of the polymerized chip and 300 g of polyester semidull chips was dried at 180° C. for 3 hours and melt spun at 285° C.into 150 denier/28 fila filaments.

The fibers were knitted into socks and dyed. The socks were found tohave excellent color presentation, gloss and sensation when touched.

Example 7

Six kilograms of pulverized linseeds, each 2 kg packed in one P.P.non-woven sack, were put into a pressure decoction machine, and 36 kg ofwater was added. After boiling at 130° C. for 3 hours, the decoction waspressurized in a hydraulic linkage to produce 25 kg of an extract whichwas then filtered and concentrated down to 8 kg.

A mixture of 3 kg of the concentrate and 97 kg of polyester chips wasused to prepare master batch chips in a typical manner.

The masterbatch chips were compounded at a weight ratio of 1:1 withordinary polyester semi dull chips, dried, and melt spun at 285° C. into150 denier/28 fila filaments using a pilot spinning machine.

The fibers were knitted into socks and dyed. The socks were found tohave excellent color presentation, gloss and sensation when touched.

Example 8

Into 99.2 wt % of polyester semidull chips was incorporated 0.8 wt % ofthe linseed oil prepared in Preparation Example 1. To this end, thelinseed oil was continuously fed into a connection between a supply pipeline for main chips and an extruder with the aid of a separate supplier(gear pump) daring which melt spinning 10 was conducted at 285±5° C. toproduce 5,300 kg of 1.4 denier/38 mm staple fibers.

The staple fibers were spun into 40S/l, followed by knitting in a singlejersey manner. The knitted goods were dyed normally. Physical propertiesof the obtained staple fibers are given in Table 2, below. Test resultsfor detrimental substances (eco full test, infant standard) aresummarized in Table 3, below. Table 4 shows properties of the staplefibers and the dyed knitted goods. The properties (elasticity, touchsensation, gloss) of the knitted goods were found to remain constanteven after 5 washes.

According to a test for antistaticity, the dyed knitted goods were foundto have a charge of 67 V (cotton cloth) and 99 V (woolen cloth) uponfrictional 25 electrification (KSK 0555:2010) {test conditions: (20±2)°C., (40±2) % RH, 400 r/min}. Also, they showed a surface resistivity of1.4×10¹² (Ω) (KSK 0170:2008) {test conditions: (20±2)° C., (40±2) % RH}{applied voltage: 100V, 60 sec}, which is highly improved, compared toordinary synthetic fibers (1.0×10¹⁴⁻¹⁵ (Ω)).

TABLE 2 ITEM Standard values Fiber of Ex. 8 Test Method Denier  1.4 ±0.05 1.39 ASTM D 1577.DIN53912 Fiber length (mm)   38 ± 1.5 38.2 KSK0327 (KOREA) Tenacity (g/de) 5.5 5.76 ATTM D 3822 Elongation (%) 30.0 ±5.0 35 ATTM D 3822 Number of crimp 13.5 ± 1.0 13.2 JIS L 1074 (JAPEN )(Number/inch)

TABLE 3 Test Item Result Criterion pH 6.2 4.0~7.5 (standard)Formaldehyde Pass Not Detected (N.D.) Heavy metal (eluted) Pass N.D.Heavy metal (acid hydrolysis) Pass N.D. Residual agricultural chemicalPass N.D. Chlorinated phenols Pass N.D. PVC plasticizer (Phthalates)Pass N.D. Organotin compound Pass N.D. Other compound (OPP) Pass N.D.Other compound (PFOS) Pass N.D. Other compound (PFOA) Pass N.D.Arylamine dye Pass N.D. Oncogenic dye Pass N.D. Allergic acidic dye PassN.D. Other restricted dye Pass N.D. Organochlorine carrier Pass N.D.Flame retardants Pass N.D. (PBB/TRIS/TEPA/PENTABDEOCTABDE/DECABDE/HBCDD) Offensive odor Pass N.D.

TABLE 4 Property Polyester Fiber of Ex. 8 Note Strength Very good Verygood Raw fiber Elongation Very good Excellent Raw fiber Bulkiness Verygood Excellent Raw fiber and raw fabric Elasticity Very good ExcellentRaw fabric after dyeing Softness Moderate Excellent Raw fiber and rawfabric Whiteness Very good Very good Raw fiber Touch Moderate ExcellentRaw fabric (upon contact Sensation with the skin) Hygroscopicity Verypoor Good Raw fabric after dyeing Dyeability Very good Excellent Rawfabric after dyeing Fragrance None Rich Raw fabric after dyeingAnti-staticity Poor Excellent Raw fabric after dyeing Gloss ModerateVery good Raw fabric after dyeing

A single jersey fabric knitted from polyester 40 s/l spun was dyed,dewatered and dried before being immersed in 5 wt % of the linseed oilof preparation Example 1 in softener-containing water (95 wt %). Then,the knitted fabric was allowed to go through a mangle roller andsubjected to a tenter process to afford a sample.

This sample showed high gloss and sensation when touched before beingwashed, but significantly decreased in gloss and touch sensation after 5washes.

Although the preferred embodiments of the present invention have beendisclosed for illustrative purposes, those skilled in the art willappreciate that various modifications, additions and substitutions arepossible, without departing from the scope and spirit of the inventionas disclosed in the accompanying claims.

1. A method for manufacturing a synthetic fiber, comprising:incorporating a plant fatty acid in an amount of from 0.1 to 10.0 wt %into a fiber-formable polymer; and melt-spinning the plant fattyacid-incorporated polymer.
 2. The method of claim 1, wherein theincorporating is carried out by coating the fiber-formable polymer withthe plant fatty acid in advance of the melt-spinning.
 3. The method ofclaim 1, wherein the incorporating is carried out by mixing the plantfatty acid with the fiber-formable polymer to afford a master batchchip.
 4. The method of claim 1, wherein the incorporating is carried outby adding the plant fatty acid to the fiber-formable polymer uponpolymerization of the fiber-formable polymer.
 5. The method of claim 1,wherein the incorporating is carried, out by continuously supplying theplant fatty acid into an extruder upon the melt spinning, using aseparate supplier.
 6. The method of claim 1, wherein the fiber-formablepolymer is a material capable of being melt spun.
 7. The method of claim1, wherein the plant fatty acid is selected from the group consisting oflinoleic acid, oleic acid, stearic acid, palmitic acid, licanic acid,ricinol acid, and a combination thereof.
 8. A synthetic fiber, preparedusing the method of claim 1, comprising a plant fatty acid in an amountof from 0.01 to 10.0 wt %.
 9. The synthetic fiber of claim 8, having asurface resistivity of 1.0×10¹⁴ (Ω) or less.
 10. The synthetic fiber ofclaim 9, having a surface resistivity of 1.0×1.0¹³ (Ω) or less.
 11. Thesynthetic fiber of claim 8, emanating a plant fragrance.